Analyzing orthogonal cutting process using SPH method by kinematic cutting tool

Abstract

In this paper, the orthogonal cutting process is studied using Smooth Particle Hydrodynamic (SPH) method by a kinematic rigid cutting tool and two work-piece material models: perfectly elastic-plastic (EPP) model and Johnson–Cook (JC) model. The kinematic tool means that if the cutting tool is assumed a rigid body then the horizontal component speed of work-piece particles at cutting tool region are modified to the cutting speed. The chip shapes of orthogonal cutting process using SPH method with kinematic and kinetic tool models are compared with the experimental results. The chip obtained by the simulation with kinematic tool is more similar to the experimental results. Von-Mises stress distribution at different states of the orthogonal cutting process is investigated. The maximum stress occurs at the shear plane and causes the formation of chip teeth. Comparisons between chips of work-pieces with two material models are investigated including different rake angles of 5, 10 and $17.5^{\circ }$ with feed rates of 0.3 and $0.4~{\rm mm}/{\rm rev}$ and the cutting forces of the process are obtained. The cutting force of process with $17.5^{\circ }$ rake angle, $0.4~{\rm mm}/{\rm rev}$ feed rate and $800~{\rm m}/{\rm min}$ cutting speed is validated using experimental result.

Keywords

• Orthogonal cutting process
• Kinematic and kinetic cutting tool
• Johnson–Cook material model
• SPH method